FoamSync 1.1.1

Critical Dome-generator reliability fix + one-click device setup.

🔴 Dome generator — full Ø3–8 m range now guaranteed buildable

The dome generator auto-fits the panel breakdown to your real stock. Until now it
auto-raised the sector count (panel width) but not the ring count — so on
large domes (Ø7 m and up) the solid top cap overflowed the block and the build
was flagged but not fixed.

1.1.1 adds automatic ring-fitting, symmetric to the existing sector-fitting:

• The 4-axis bevel limit caps how high the rings reach, so a bigger dome leaves a
  wider apex → a wider flat cap. The generator now auto-raises n_rings until
  that cap fits the stock (finer rings reach higher and shrink the cap).
• Verified across the whole catalogue from a 1000×1000×1000 mm block:
  Ø3–6 m → 5 rings · Ø7 m → 6 · Ø8 m → 9. Every panel fits, zero fit warnings.
• A clear note explains any auto-adjustment; if even the maximum ring count can't
  fit the cap, the build hard-blocks with an actionable message (deeper stock /
  smaller dome / oculus) instead of emitting an un-cuttable panel.

Result: the dome generator now reliably produces a cuttable hemisphere panel kit
(with tooth/slot locks, kerf, BOM and assembly order) across the full Ø3–8 m range.

🟢 Device Probe + one-click connection setup

• New Device Probe engine: plug the controller in over USB and it reads the
  full identity — board (USB VID/PID), firmware family/version (GRBL / grblHAL /
  Marlin / FluidNC), axis count, steps/mm, travel, pins/drivers — and writes a
  versioned JSON report. Catches the classic UNO-R3-vs-R4 mix-up before you connect.
• SETUP → SETTINGS → HARDWARE → “SCAN DEVICE” interrogates the plugged-in
  controller and auto-selects the matching board profile + firmware; “IMPORT
  REPORT…” does the same from a report file scanned on another PC.
• Never assumes what it can't verify: shield version and axis directions are flagged
  for confirmation, travel limits are opt-in.

Notes

• No config migration required.
• All prior generators, locks, kerf, BOM and cut-gates unchanged.

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Build: obfuscated (PyArmor BCC + mix-str), secret-leak-scanned, boot-smoke-tested.
Installer: FoamSync-1.1.1-Setup.exe (~90.9 MB)
SHA256: 44e799a71fbf90f311f2ef682f82d5fa59d17547849f78ebe651a91060851bcf

FoamSync 1.1.0

Professional CAM software for 4-axis hot-wire CNC foam cutters. Design a part, FoamSync computes the synchronized four-axis wire toolpath, and your machine cuts EPS / XPS / PU foam — with optional 5th rotary-axis support. Drives Marlin, GRBL and GRBL-H-Par out of the box.

🌐 foamsyncstudio.com  ·  📖 Documentation  ·  💬 support@foamsyncstudio.com

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⬇️ Download

FoamSync-1.1.0-Setup.exe — Windows 10 / 11 (64-bit).

A 7-day trial runs out of the box — no key required to evaluate. The trial runs in virtual-driver mode (no real machine) with watermarked output until a paid licence is activated. The standalone Machine-ID tool lives on the download page.

Verify the installer (SHA-256):

9bebc37389d27f91ce6e6ba88505aa1b2572417e522d08e583653355631ac541

Get-FileHash .\FoamSync-1.1.0-Setup.exe -Algorithm SHA256

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✨ Highlights of this release

FoamSync now runs the shop, not just the cutter. 1.1.0's headline is a full order-to-production CRM, included with Studio — a whole new category alongside the CAM engine, which is why this is a 1.1 release rather than a patch.

• 🏭 FoamSync CRM (Studio). A new OFFICE QUEUE connects your cutter to the CRM at crm.foamsyncstudio.com: the office authors and freezes production specs, the shop pulls its queue and opens each job with the exact generator parameters, and FoamSync pushes real cut times and block counts back automatically — so planning and costing run on actual numbers, not guesses. Orders, materials, day-planning, per-order costing and §14-compliant Rechnungen all live in the CRM. Connect a machine with one revocable token (CRM → Settings → Machines). How it works →
• 🔄 5th-axis block indexing. Turn the whole foam block a quarter-turn to present another face to the wire — one click on the 5TH AXIS cell in the RUN DRO (right-click turns it back). Cutting stays normal 4-axis.
• 🔌 Smarter machine setup. Connection is now board- and shield-aware — it tells a UNO R3 from an R4, RAMPS or FluidNC, not just the firmware — with a guided connect. (A dedicated USB hardware-probe tool is on the way.)
• 🛡️ Hard cut-safety gates. A toolpath that would cross another part or overflow the block is now refused, not cut — an extra guard on top of the pre-cut wire-safety pass.
• 🏛️ BUILD dome refinements. Fit-to-stock checks, lock-mate verification and a cut-list / assembly guide on parametric domes.

Licensing, key format and activation are unchanged — existing keys keep working. Pull 1.0.17 and ship 1.1.0.

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What's inside

CAM core — included in every tier
4-axis G-code post-processor (synced X/Y + independent U/V) · auto-nesting across parts (true-pitch packing + shared cut lines on identical parts) · bounding-box collision check · pre-cut wire-safety validation + hard cut-safety gates · on-screen real-machine jogging · live 4-axis DRO (+ optional 5th rotary with 90° block indexing) · heater control (external / board PWM / PID) · SHAPES primitives + SVG / DXF import · material library (EPS / XPS / PU + custom) · Quick Lab calibration · controller + board auto-detect (Marlin / GRBL / GRBL-H-Par, board/shield-aware).

Pro Packs — mix only the generators you need

• 🏛️ BUILD — parametric domes, vaults and buildings
• ✈️ AERO — NACA-4 airfoils, tapered wings, spar slots, 4-axis tilted cuts
• 🌡️ THERMAL — pipe-shell unfolder + thermal panels with half-lap joints
• 🎨 DECOR — catalogue cornice / moulding profiles, a freehand Grid Sketch editor, and foam lettering & signs from any installed font

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💳 Licensing

Three tiers — Lite, Pro (mix any of the four packs), and Studio (everything, 3 machine seats, plus the FoamSync CRM). One-time perpetual keys or monthly / annual subscriptions, each with 12 months of updates included. Full pricing → foamsyncstudio.com/pricing.

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_{© Balcore Systems · CAM software for hot-wire EPS / XPS / PU foam cutting · Questions? support@foamsyncstudio.com}

FoamSync 1.0.17

Professional CAM software for 4-axis hot-wire CNC foam cutters. Design a part, FoamSync computes the synchronized four-axis wire toolpath, and your machine cuts EPS / XPS / PU foam — with optional 5th rotary-axis support. Drives Marlin, GRBL and GRBL-H-Par out of the box.

🌐 foamsyncstudio.com  ·  📖 Documentation  ·  💬 support@foamsyncstudio.com

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⬇️ Download

FoamSync-1.0.17-Setup.exe — Windows 10 / 11 (64-bit).

A 7-day trial runs out of the box — no key required to evaluate. The trial runs in virtual-driver mode (no real machine) with watermarked output until a paid licence is activated. The standalone Machine-ID tool lives on the download page.

Verify the installer (SHA-256):

b0d358a9ed8372253fa96eb9724d170a0a196143dba34d0143569ac424a95c52

Get-FileHash .\FoamSync-1.0.17-Setup.exe -Algorithm SHA256

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What's inside

CAM core — included in every tier
4-axis G-code post-processor (synced X/Y + independent U/V) · auto-nesting across parts · bounding-box collision check · pre-cut wire-safety validation · on-screen real-machine jogging · live 4-axis DRO (+ optional 5th rotary) · heater control (external / board PWM / PID) · SHAPES primitives + SVG / DXF import · material library (EPS / XPS / PU + custom) · Quick Lab calibration · controller auto-detect.

Pro Packs — mix only the generators you need

• 🏛️ BUILD — parametric domes, vaults and buildings
• ✈️ AERO — NACA-4 airfoils, tapered wings, spar slots, 4-axis tilted cuts
• 🌡️ THERMAL — pipe-shell unfolder + thermal panels with half-lap joints
• 🎨 DECOR — catalogue cornice / moulding profiles, a freehand Grid Sketch editor, and foam lettering & signs from any installed font

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✨ Highlights of this release

This is an engine release focused on the BUILD generators — same features, less foam and faster cuts.

• Tighter nesting on domes, vaults and buildings. Large arch and wall panels now pack into noticeably fewer foam blocks — a 6 × 10 m barrel vault drops from 49 to 30 blocks, with material-fill now reported accurately on the layout.
• Continuous-serpentine cutting. Each foam block's parts are cut as one continuous path instead of a separate wire entry per part — roughly 85 % fewer wire entries on a typical dome / vault / building job. Fewer entries means faster cuts and fewer lead-in marks, for cleaner parts. Every part is still cut as its own profile; only the travel between them is optimised.
• Panels are auto-oriented to lie flat for denser, cleaner layouts (tapered 4-axis parts are left untouched, as they must be).

No changes to licensing, key format or activation — existing keys keep working. Pull 1.0.16 and ship 1.0.17.

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💳 Licensing

Three tiers — Lite, Pro (mix any of the four packs), and Studio (everything, 3 machine seats). One-time perpetual keys or monthly / annual subscriptions, each with 12 months of updates included. Full pricing → foamsyncstudio.com/pricing.

---

_{© Balcore Systems · CAM software for hot-wire EPS / XPS / PU foam cutting · Questions? support@foamsyncstudio.com}

FoamSync 1.0.16

Professional CAM software for 4-axis hot-wire CNC foam cutters. Design a part, FoamSync computes the synchronized four-axis wire toolpath, and your machine cuts EPS / XPS / PU foam — with optional 5th rotary-axis support. Drives Marlin, GRBL and GRBL-H-Par out of the box.

🌐 foamsyncstudio.com  ·  📖 Documentation  ·  💬 support@foamsyncstudio.com

---

⬇️ Download

FoamSync-1.0.16-Setup.exe — Windows 10 / 11 (64-bit).

A 7-day trial runs out of the box — no key required to evaluate. The trial runs in virtual-driver mode (no real machine) with watermarked output until a paid licence is activated. The standalone Machine-ID tool lives on the download page.

Verify the installer (SHA-256):

e0b78889b380adba48aa29c22cc7cb6a855fc175275323e22374497c8de6d414

Get-FileHash .\FoamSync-1.0.16-Setup.exe -Algorithm SHA256

---

What's inside

CAM core — included in every tier
4-axis G-code post-processor (synced X/Y + independent U/V) · auto-nesting across parts · bounding-box collision check · pre-cut wire-safety validation · on-screen real-machine jogging · live 4-axis DRO (+ optional 5th rotary) · heater control (external / board PWM / PID) · SHAPES primitives + SVG / DXF import · material library (EPS / XPS / PU + custom) · Quick Lab calibration · controller auto-detect.

Pro Packs — mix only the generators you need

• 🏛️ BUILD — parametric domes, vaults and buildings
• ✈️ AERO — NACA-4 airfoils, tapered wings, spar slots, 4-axis tilted cuts
• 🌡️ THERMAL — pipe-shell unfolder + thermal panels with half-lap joints
• 🎨 DECOR — catalogue cornice / moulding profiles, a freehand Grid Sketch editor, and foam lettering & signs from any installed font

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✨ Highlights of this release

• New DECOR pack — the fourth Pro Pack: a catalogue of real cornice / moulding profiles scaled to your dimensions, the freehand Grid Sketch custom-contour editor (snap grid · curved edges · inner holes · trace-over-image · saved-shape library), and a Text generator for foam letters and signs from any font.
• Reworked 3D viewport — proper orbit / zoom / pan, a navigation gizmo, and automatic part framing.
• UI polish across the cockpit and the generator pages.

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💳 Licensing

Three tiers — Lite, Pro (mix any of the four packs), and Studio (everything, 3 machine seats). One-time perpetual keys or monthly / annual subscriptions, each with 12 months of updates included. Full pricing → foamsyncstudio.com/pricing.

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_{© Balcore Systems · CAM software for hot-wire EPS / XPS / PU foam cutting · Questions? support@foamsyncstudio.com}